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Five things manufacturers tell me

5 slides · Manufacturing · 1080 x 1350
01Manufacturing
VP.
What I hear on the floor

The plan lives
on a whiteboard

And the whiteboard is out of date by ten in the morning.

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02The pattern
VP.
Five, every time

What comes up

01
Stock is a register
Nobody knows the level without walking the floor and counting.
02
Instructions are verbal
Do this, go there. Nothing records what was assigned or skipped.
03
Orders arrive three ways
WhatsApp, phone and walk in. No single place to see them.
04
Quality is caught late
After it shipped, because nothing tracks stage by stage.
05
Tally does not touch ops
The gap between what Tally knows and what the floor does is filled by people and paper.
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03The gap
VP.
End of day

Reconciliation, before and after

Today
An hour of cross checking
Three people asked the same question
Numbers agreed on by memory
After a Reset
One screen, five minutes
The system already knows
Numbers agreed on by record
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04Where we start
VP.
First three modules

Usually the same three

Work orders, stock in and out with a real count, and quality captured at the station.

Stock check, done twice
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05Next
VP.
One ask

Which of the five
is worst on your floor?

Tell me the one. I will tell you honestly whether it is a 30 day job or not.

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